B Cylinder Head Capscrew - Torque Plus Angle (T594)

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Topic No. Rev. Level Topic Date Group No. 98T2-13 01-Sep-1998 02 Expiration Date (U.S. and Canada): Expiration Date (International): Engine Family Fuel System Plant From Build Date 4B, B3.

1 Topic No. Rev. Level Topic Date Group No. 98T Sep Expiration Date (U.S. and Canada): Expiration Date (International): Engine Family Fuel System Plant From Build Date 4B, B3.9 All Default 01-Jan Dec B, ISB, QSB5.9, B5.9 All Default 01-Jan Dec-9999 To Design Application All Market Application All B Cylinder Head Capscrew - Torque Plus Angle (T594) This Service Parts Topic pertains to the new Cylinder Head Capscrew - Torque Plus Angle procedure. This service parts topic supersedes 91T2-9A. Remove 91T2-9A from your files. The purpose of this service parts topic is to revise the torque plus angle procedure. This procedure has been revised due to cylinder head gasket relaxation and to obtain proper cylinder head capscrew torque. NOTE Recommended Service Tools: Cylinder head capscrew length gauge, Part No Torque angle gauge for 1/2-inch drive, Part No Torque angle gauge for 3/4-inch drive, Part No Torque wrench validator, Part No Cylinder Head Capscrew Removal Sequence 18 mm Remove the cylinder head capscrews in the sequence shown. (1 of 19)6/9/2006 6:01:21 AM

WARNING The component weighs 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get assistance to lift the component. Remove the cylinder head from the block.

2 WARNING The component weighs 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get assistance to lift the component. Remove the cylinder head from the block. Cylinder head weight: Four Cylinder - 36 kg [80 lb] Six Cylinder kg [114 lb] NOTE: Inspect the coolant passages. A large buildup of rust and lime will require removal of the cylinder block for cleaning in a hot tank. (2 of 19)6/9/2006 6:01:21 AM

3 Straightedge and Feeler Gauge Use a straightedge and feeler gauge to measure the overall flatness of the cylinder block. The overall flatness end-to-end and side-to-side must not exceed mm [0.003 in]. Inspect the combustion deck for any localized dips or imperfections. If present, the cylinder block head deck must be ground. Refer to the alternate repair manual for regrinding/ milling procedures and limits. Cylinder Head - Precheck Clean the cylinder head with solvent. (3 of 19)6/9/2006 6:01:21 AM

Inspect the cylinder head for obvious damage that would prohibit reuse. Check for cracks and damage to the deck surface that would result in loss of sealing.

4 Inspect the cylinder head for obvious damage that would prohibit reuse. Check for cracks and damage to the deck surface that would result in loss of sealing. CAUTION Do not use caustic or acidic solutions to clean the cylinder head capscrews. The use of these solutions can damage the capscrew. (4 of 19)6/9/2006 6:01:21 AM

5 Cylinder Head Capscrews Use a petroleum-based solvent to clean the capscrews. Clean the capscrews thoroughly with a wire brush, a soft wire wheel, or use a nonabrasive bead blast to remove deposits from the shank and threads. Inspect the cylinder head capscrews for damaged threads, corroded surfaces, or a reduced diameter (due to stretching). NOTE: Do not reuse a capscrew that has damaged threads or a reduced diameter from having been stretched. (5 of 19)6/9/2006 6:01:21 AM

Do not use cylinder head capscrews under the following conditions: 1. Corrosion or pitting exceeds 1 sq cm [0.155 sq in] in area. 2. Acceptable = 3/8 x 3/8 inch 3. Unacceptable = 1/2 x 1/2 inch 4.

6 Do not use cylinder head capscrews under the following conditions: 1. Corrosion or pitting exceeds 1 sq cm [0.155 sq in] in area. 2. Acceptable = 3/8 x 3/8 inch 3. Unacceptable = 1/2 x 1/2 inch 4. Corrosion or pitting exceeds 0.12 mm [0.005 in] in depth. 5. Corrosion or pitting is located within 3.2 mm [1/8 in] of the fillet. 6. Corrosion or pitting is located within 3.2 mm [1/8 in] of the threads. 7. Stretched beyond free length maximum. Refer to the measurement procedure below. (6 of 19)6/9/2006 6:01:21 AM

7 Cylinder Head Capscrew Reuse Guidelines Service Tool Part No Free-Length Measurement To check the capscrew free length, place the head of the capscrew in the appropriate slot with the flange against the base of the slot. NOTE: If the capscrews are not damaged, they can be reused throughout the life of the engine unless the specified free length is exceeded. Capscrew Free Length mm Short Medium Long in (7 of 19)6/9/2006 6:01:21 AM

8 If the end of the capscrew touches the foot of the gauge, the capscrew is too long and must be discarded. NOTE: Do not use any cylinder head capscrews that are cracked, pitted, or rusted in the shank or the threaded areas. Immediately after cleaning and inspecting, apply a film of clean lubricating oil to the capscrews that are to be used again. (8 of 19)6/9/2006 6:01:21 AM

9 Installation NOTE: Make sure the head gasket is correctly aligned with the holes in the cylinder block. The cylinder block and head must be clean and dry. Position the gasket onto the dowels. CAUTION Do not drop the cylinder head on the cylinder head gasket. The gasket material can be damaged. (9 of 19)6/9/2006 6:01:21 AM

Carefully install the cylinder head onto the gasket and cylinder block. NOTE: Make sure the cylinder head is installed onto the dowels in the cylinder block.

10 Carefully install the cylinder head onto the gasket and cylinder block. NOTE: Make sure the cylinder head is installed onto the dowels in the cylinder block. Use clean 15W-40 oil to coat the cylinder head capscrew threads and underneath the head flange. Allow excess oil to drain from the capscrew threads. (10 of 19)6/9/2006 6:01:21 AM

11 Install capscrews in the cylinder head. NOTE: Be sure to install the six capscrews into the holes underneath the injectors. NOTE: The top of the cylinder head capscrew is identified with an angle marking. The cylinder head capscrews must be tightened by using the three-step torque plus angle method, described as follows: Lubricate the threads and under the capscrew head of the cylinder head capscrews with clean engine oil. (11 of 19)6/9/2006 6:01:21 AM

12 1. Follow the numbered sequence, and tighten all the capscrews: Follow the numbered sequence, and recheck the torque on all the capscrews. Torque Value: (Step one) 90 N m [66 ft-lb] 2. Follow the numbered sequence, and tighten only the six long capscrews. Follow the numbered sequence and check again the torque on the six long capscrews. Torque Value: (Step two) 120 N m [90 ft-lb] 3. Repeat steps 1 and 2 because of cylinder head relaxation and to obtain proper cylinder head torque requirements. (12 of 19)6/9/2006 6:01:21 AM

13 4. Follow the numbered sequence, and turn the capscrew 90 degrees as indicated on the capscrew head. (13 of 19)6/9/2006 6:01:21 AM

14 To turn the capscrew to the desired angle accurately, align the capscrew with the small dot and window that are marked on the capscrew head, or use recommended service tool, Part No , torque angle gauge for 1/2-inch drive and/or Part No , torque angle gauge for 3/4-inch drive. Mark the cylinder head adjacent to the dot on the capscrew head. This mark will serve as an indexing aid. (14 of 19)6/9/2006 6:01:21 AM

15 Rotate the capscrew until the mark that has been made on the cylinder head falls into the window on the capscrew head. Service Tip: Use a permanent marker to mark the socket corresponding to one of the flats of the socket hex. (15 of 19)6/9/2006 6:01:21 AM

16 After the torque has been applied, mark the cylinder head at the location of the dot. (16 of 19)6/9/2006 6:01:21 AM

17 Position the socket on the capscrew such that the mark on the socket is at the same point as the window on the capscrew. Turn the socket until the mark on the socket aligns with the mark on the cylinder head. (17 of 19)6/9/2006 6:01:21 AM

18 Cylinder Head Capscrew Information for B Series Engines Each capscrew has been marked with symbols and an angle specification to simplify the tightening procedure. The capscrew part numbers can be identified by inspecting the marks on the capscrew head. Below is a list of the pre-'91 capscrews and capscrews with the identifying marks on the head. NOTE Do not use pre-'91 cylinder head capscrews in a '91 engine. The '91 cylinder head capscrews can be used in a pre-'91 engine. Pre-'91 Capscrew Part No. Length New '91 Capscrew Part No. Length Short Short Medium Medium Long Long 1991B Series Pre-91B Series Copyright 1998 Cummins Engine Company, Inc. All rights reserved (18 of 19)6/9/2006 6:01:21 AM

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TO C. Install CAUTION

TO C. Install CAUTION Install TO C CAUTION Make sure the cylinder head gasket is correctly aligned with holes in the cylinder block. If not aligned properly, it can cause engine damage. Position the new cylinder head gasket